101603-4802 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034802 1156023282


101603-4802 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-4802 1016034802
ISUZU 1156023282 1156023282

Service parts 101603-4802 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4590
3. GOVERNOR 105931-4981
4. SUPPLY PUMP 105220-4791
5. AUTOM. ADVANCE MECHANIS 105644-0350
6. COUPLING PLATE 105661-0730
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6241
11. Nozzle and Holder 1-15300-142-0
12. Open Pre:MPa(Kqf/cm2) 18.1(185)
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-5860
15. NOZZLE SET

Include in #1:

101603-4802 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101603-4802 1016034802
ISUZU 1156023282 1156023282


Zexel num
Bosch num
Firm num
Name
101603-4802 
 
1156023282  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1 * K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8140
Bosch type code   EF8511/9A
Nozzle   105780-0000
Bosch type code   DN12SD12T
Nozzle holder   105780-2080
Bosch type code   EF8511/9
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   131424-4920
Overflow valve opening pressure kPa   127 107 147
Overflow valve opening pressure kgf/cm2   1.3 1.1 1.5
Tester oil delivery pressure kPa   157 157 157
Tester oil delivery pressure kgf/cm2   1.6 1.6 1.6
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.6 3.55 3.65
Rack position
Point A
  R=A
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   -
Rack position   10.8
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   54.3 52.7 55.9
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   290 290 290
Average injection quantity mm3/st.   8 6.7 9.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.8)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   54.3 53.3 55.3
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(10.8)
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   60 56.8 63.2
Fixing the lever   *
Timer adjustment
Pump speed r/min   1310--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1260
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4802
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1
----------
T1=C78
----------

Speed control lever angle

Test data 101603-4802
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=(33deg)+-3deg

Stop lever angle

Test data 101603-4802
N:Pump normal S:Stop the pump. (1)Stopper bolt setting
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 ACS

Test data 101603-4802
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=900r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.8)mm Rb=R1-0.5mm Pa=84.5+-2.7kPa(634+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54.3+-1cm3/1000st Q2=(40.4)+-1.6cm3/1000st

Timing setting

Test data 101603-4802
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(60deg)




Have questions with 101603-4802?





Group cross 101603-4802 ZEXEL

Isuzu 

 
1156023280 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023281 
INJECTION-PUMP ASSEMBLY
6BG1
101603-4802  
 
1156023282 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022151 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156022152 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156022153 
INJECTION-PUMP ASSEMBLY
6BG1-TC
9 400 615 097 
1156022154 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023710 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156023711 
INJECTION-PUMP ASSEMBLY
6SA1
9 400 615 098 
1156023712 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156022741 
INJECTION-PUMP ASSEMBLY
6BD1T
9 400 615 099 
1156022742 
INJECTION-PUMP ASSEMBLY
6BD1-T
 
1156023032 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023033 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023034 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023035 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023036 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023037 
INJECTION-PUMP ASSEMBLY
6BG1-TC
9 400 615 100 
 
INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

9 400 615 100 
1156023038 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023720 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023721 
INJECTION-PUMP ASSEMBLY
6BG1TC
9 400 615 101 
 
INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

9 400 615 101 
1156023722 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156024300 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156024301 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156024310 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022602 
INJECTION-PUMP ASSEMBLY
6BG1S
9 400 615 102 
1156022603 
INJECTION-PUMP ASSEMBLY
6BG1-S
 
1156024320 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156024321 
INJECTION-PUMP ASSEMBLY
6BG1S
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